Spray-dried compositions capable of retaining volatile compounds and methods of producing the same

ABSTRACT

The present invention relates to spray-dried compositions capable of retaining volatile compounds and methods relating to the same. The present invention also relates to the powders produced by such methods.

This patent application is a continuation of U.S. application Ser. No.14/002,257 filed Feb. 18, 2014, which is the National Stage ofInternational Application No. PCT/US2012/027435 filed Mar. 2, 2012,which claims the benefit of priority from U.S. Provisional ApplicationSer. No. 61/449,440, filed Mar. 4, 2011, the contents of which areherein incorporated by reference in their entirety.

INTRODUCTION Background of the Invention

In the food industry, spray drying, freeze-drying, vacuum continuousbelt drying, and reduced pressure-low temperature drying with a vacuumdryer have been used to produce dry powders of flavor ingredients suchas, for example, dry extracts of animals and plants.

Spray drying is a common industrial method for drying liquid solutionsor slurries by spraying into a stream of hot gas. It is a rapid,one-step process for converting the feed liquid into a powder. Usuallythe drying gas is air, but nitrogen can also be used for specialproducts needing oxygen-free conditions. The most common feed materialsare aqueous-based solutions, emulsions and suspensions, where water isevaporated in the dryer. The liquid feed is fed to an atomizer, which isa device that breaks up the liquid stream into tiny droplets. Thisatomization takes place within the drying chamber so that the dropletsare immediately exposed to hot air that initiates rapid moistureevaporation. The droplets become small particles of powder as themoisture is evaporated and they fall to the bottom of the dryingchamber. Pressure nozzles, rotary disks, two-fluid nozzles, and the likeare used as the atomizing unit. In many cases, the mean particle size(diameter) of the resulting dry powder is about 20 μm to 500 μm, and thedrying time is as short as 5 to 30 seconds (see, Handbook of Chemistryand Engineering (1999) revised sixth edition, Maruzen Corporation, p.770, p. 780). A four-fluid nozzle has also been developed, which hasenabled mass-scale spray drying with a liquid droplet having a meanparticle size of several micrometers.

The spray drying method is used in many cases of mass scale production.In general, to produce a large volume of powder in a short period oftime, a solution or slurry is fed at a fast feed rate into a spraydryer, while the inlet temperature of the spray dryer and the outlettemperature thereof are elevated as high as possible, to dry the slurryat a high speed. For example, milk is dried at an inlet temperature ofthe spray dryer of 150 to 250° C. and yeast is dried at the inlettemperature of 300 to 350° C. Drying at such high temperatures maynegatively impact the flavor of the raw material itself and produce adry powder with a burned odor. However, spray drying at a lowtemperature to avoid these disadvantages can increase process times andcosts. See US 2005/0031769 and U.S. Pat. No. 6,482,433.

Spray-dried encapsulated flavors are created during the drying processwhen the aqueous carrier slurry forms a shell around the normallyoil-based flavor core. During the drying process, a thin film of carriermaterial rapidly forms around the atomized droplet and selectivelyallows water to evaporate while retaining the flavor oil (Thijssen &Rulkens (1968) De Ingenieur 80:45-56). The shell protects the coreagainst deterioration and volatile evaporation, but also allows the coreto be released under desired conditions, for example, dissolution inwater.

There has been a long felt need to spray dry natural and syntheticmaterials to provide intense fresh, authentic consumer preferred flavorsin foodstuffs and other flavor-containing products. Likewise, there is asimilar need to spray dry natural and synthetic materials to provideintense, fresh, authentic consumer preferred fragrances in consumerproducts.

SUMMARY OF THE INVENTION

The present invention is a spray-dried flavor composition containing aspray-dried flavor that has volatile compounds, wherein the volatilecompounds are present in an amount that is at least 20% of the volatilecompounds originally contained in the flavor.

The invention also provides a spray-dried flavor composition produced byspray drying a flavor that contains volatile compounds in a spray dryerhaving an inlet temperature of less than 100° C. and an air inlet dewpoint −10° C. to 5° C., wherein the volatile compounds are present inthe spray-dried flavor composition in an amount that is at least 20% ofthe volatile compounds originally contained in the flavor.

The invention also provides a stable spray-dried flavor compositionproduced by spray drying a flavor that that contains volatile compoundsin a spray dryer having an inlet temperature of less than 100° C. and anair inlet dew point −10° C. to 5° C., wherein the volatile compounds arepresent in the spray-dried flavor composition in an amount that is atleast 20% of the volatile compounds originally contained in the flavor.

A method for producing a spray-dried composition capable of retainingvolatile compounds is also embraced by the present invention. Inaccordance with this method, a flavor containing volatile compounds isspray dried in a spray dryer having an inlet temperature of less than100° C. and an air inlet dew point −10° C. to 5° C. to obtain aspray-dried flavor composition, wherein the volatile compounds arepresent in the spray-dried flavor composition in an amount that is atleast 20% of the volatile compounds originally contained in the flavor.

In accordance with certain embodiments of the composition and methods ofthis invention, the spray-dried composition may be subjected to anadditional drying step in a fluid-bed chamber attached at the spraydryer outlet, wherein the temperature of the air of the fluid-bed unitis at or below the outlet temperature of the spray dryer. In otherembodiments, the volatile compounds are acetaldehydes, dimethylsulfides, ethyl acetates, ethyl propionates, methyl butyrates, or ethylbutyrates. In yet other embodiments, the volatile compounds have aboiling point of less than 200° C., less than 100° C., or less than 60°C.

In further embodiments, the composition fed to the dryer may furtherinclude a carrier material and/or a solvent, such as a volatile solvent,wherein the flavor and carrier comprise 40% and 70% as dry solidmaterial of the total composition. For the purpose of the invention, adry solid material is defined as a combination of carrier and flavormaterials. In yet other embodiments, the flavor is prepared as anemulsion and the volatile compounds are present in the emulsion in anamount that is at least 80% of the volatile compounds originallycontained in the flavor. Still further embodiments include the use ofnitrogen or carbon dioxide in the spray dryer. In certain embodiments,the air inlet temperature is in the range of 40° C. to 99° C. Flavorcompositions with a water activity in the range of 0.1 to 0.6 and highintensity flavor compositions and their use in, e.g., a chewing gum orbeverage are also provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a comparison of sensory profiles of Orange Flavor betweensamples produced under different RH/Temperature conditions in a beveragetasting solution. *Directionally different, **Significantly different atp=0.05

FIG. 2 shows a comparison of time intensity profiles of Orange Flavorbetween samples produced under different humidity/temperature conditionsin sugar-free chewing gum. **Significantly different at p=0.05 at theseelapsed times.

FIG. 3 shows a comparison of sensory profiles of Berry Flavor betweensamples produced under different humidity/temperature conditions in abeverage tasting solution. **Significantly different at p=0.05.

FIG. 4 shows a comparison of time intensity profiles of Berry Flavorbetween samples produced under different humidity/temperature conditionsin sugar-free chewing gum. **Significantly different at p=0.05 at theseelapsed times.

FIG. 5 is a diagram of dryer airflow used in the production of theinstant composition.

DETAILED DESCRIPTION OF THE INVENTION

It has been found that commercially available spray dryer nozzles,geometries, and circulation patterns can be used in methods of producingpowders with high volatile retention and high flavor intensity, evenwhen drying for an extended amount of time. In particular, when aconventional spray dryer is used with an inlet temperature of less than100° C. and a dew point −10° C. to 5° C., higher levels of volatilecompounds can be retained. Because of the increased efficiency of themethod described herein, drying of flavor compositions containingvolatile compounds can be achieved at relatively low temperaturescompared to conventionally used methods. The resulting spray-driedflavor composition has high intensity flavor and has a highflavor/fragrance quality that is authentic to the natural source.Surprisingly, these flavor compositions maintain high flavor intensityand flavor/fragrance quality in various end-use applications afterlong-term storage.

The invention also provides a stable spray-dried flavor compositionproduced by spray drying a flavor that that contains volatile compoundsin a spray dryer having an inlet temperature of less than 100° C. and anair inlet dew point −10° C. to 5° C., wherein the volatile compounds arepresent in the spray-dried flavor composition in an amount that is atleast 20% of the volatile compounds originally contained in the flavor.For the purpose of this invention stability is defined as a flavorquality and intensity that remains acceptable for use in end useapplications. Preferably, a stable spray-dried flavor composition has ashelf-life of up to three years depending on storage conditions.Consumer data, as demonstrated in the examples herein, showedstatistically significant preference for the flavors composition of thepresent invention. The consumer preferred quality of the flavorcomposition is further supported by the attributes selected by consumersto describe the flavor quality of the prototypes.

Therefore, the present invention is a spray-dried flavor composition anda method for producing such a composition. In accordance with thepresent invention, a spray-dried flavor composition containing one ormore volatile compounds is produced by spray drying a flavor in a spraydryer with an inlet temperature of less than 100° C. and a dew point−10° C. to 5° C. so that a dry powder is obtained. In certainembodiments, the resulting spray-dried composition is further dried in afluidized bed. As a result of the instant method, the spray-dried flavorcomposition retains at least 20% of the volatile compounds originallycontained in the flavor.

Unless otherwise specified, a flavor of the invention is a flavor thatcontains one or more volatile compounds. A variety of flavors can beused in accordance with the present invention. Flavor may be chosen fromsynthetic flavor and flavoring aromatics, and/or oils, oleo resins andoil extracts derived from plants, leaves, flowers, fruits, andcombinations thereof. Representative flavor oils include, but are notlimited to, spearmint oil, cinnamon oil, peppermint oil, clove oil, bayoil, thyme oil, cedar leaf oil, oil of nutmeg, oil of sage, and oil ofbitter almonds. Also useful are artificial, natural or synthetic fruitflavors such as vanilla, chocolate, coffee, cocoa and citrus oil,including lemon, orange, grape, lime and grapefruit, and fruit essencesincluding apple, pear, peach, strawberry, raspberry, cherry, plum,pineapple, apricot and so forth. These flavors can be used individuallyor in admixture.

The volatile compounds of the instant flavor may include, but are notlimited to, acetaldehyde, dimethyl sulfide, ethyl acetate, ethylpropionate, methyl butyrate, and ethyl butyrate. Flavors containingvolatile aldehydes or esters include, e.g., cinnamyl acetate,cinnamaldehyde, citral, diethylacetal, dihydrocarvyl acetate, eugenylformate, and p-methylanisole. Further examples of volatile compoundsthat may be present in the instant flavor oils include acetaldehyde(apple); benzaldehyde (cherry, almond); cinnamic aldehyde (cinnamon);citral, i.e., alpha citral (lemon, lime); neral, i.e., beta citral(lemon, lime); decanal (orange, lemon); ethyl vanillin (vanilla, cream);heliotropine, i.e., piperonal (vanilla, cream); vanillin (vanilla,cream); alpha-amyl cinnamaldehyde (spicy fruity flavors); butyraldehyde(butter, cheese); valeraldehyde (butter, cheese); citronellal (modifies,many types); decanal (citrus fruits); aldehyde C-8 (citrus fruits);aldehyde C-9 (citrus fruits); aldehyde C-12 (citrus fruits); 2-ethylbutyraldehyde (berry fruits); hexenal, i.e., trans-2 (berry fruits);tolyl aldehyde (cherry, almond); veratraldehyde (vanilla);2,6-dimethyl-5-heptenal, i.e., melonal (melon); 2-6-dimethyloctanal(green fruit); and 2-dodecenal (citrus, mandarin); cherry; or grape andmixtures thereof. The composition may also contain taste modulators andartificial sweeteners.

The physical, chemical, and odor properties of selected volatilecompounds are presented in Table 1.

TABLE 1 Water Boiling Solubility MW Point (g/L, Odor Compound (g/mol) (°C.) approx.) Descriptors* acetaldehyde 44.05 21 soluble pungent;ethereal dimethyl 62.02 36 insoluble cabbage sulfide ethyl acetate 88.1177 90 ethereal; fruity ethyl 102.13 99 14 sweet; fruity; propionateethereal methyl 102.13 102 15 fruity; butyrate pineapple ethyl 116.16121 6 fruity; butyrate pineapple *The Good Scents Company and MerckIndex, 12^(th) Ed.

The instant invention is particularly useful in processing flavors withvolatile compounds having a boiling point of less than 200° C., lessthan 150° C., less than 120° C., less than 100° C., less than 80° C.,less than 60° C., less than 40° C., less than 20° C., or less than 0° C.Using such flavors, higher levels of volatile compounds are retained,which results in a sensory perceivable difference over conventionaldrying processes.

In certain embodiments, the invention further includes the use of acarrier material to enhance processing productivity and flavorintensity. Such carriers can include any sugar, sugar derivatives,modified starch, proteins, celluloses, salts, dextrins, gums, sugaralcohols, polyols, peptides, acids, carbohydrates or hydrocolloids.Particular examples of suitable materials include sugars such assucrose, glucose, lactose, levulose, trehalose, fructose, maltose,ribose, dextrose, isomalt, sorbitol, mannitol, xylitol, lactitol,maltitol, pentatol, arabinose, pentose, xylose, galactose; hydrogenatedstarch hydrolysates; maltodextrins or dextrins (soluble fiber);hydrocolloids such as agar or carrageenan; gums; polydextrose; proteinssuch as soy and whey protein isolates and hydrolyzates, and sodiumcaseinates; and derivatives and mixtures thereof. The carrier can beselected based upon, amongst other factors, the desired flavor,authentic taste and intensity to be achieved.

In some embodiments, the flavor and optional carrier material aredissolved or emulsified in a solvent and subsequently spray-dried. Insome embodiments, the solvent is water. In other embodiments, thesolvent is not water. In yet further embodiments, the solvent is avolatile solvent. In still other embodiments, the solvent is a mixtureof water and a volatile solvent. As is known in the art, a volatilesolvent is a nonaqueous liquid with solvent properties with thecharacteristic of evaporating readily at room temperature andatmospheric pressure. Volatile solvents of particular use in accordancewith the present invention include, but are not limited to, ethanol,ethyl acetate, acetone.

Flavor emulsions can be prepared according to standard preparationprocedures. Briefly, the practice involves dispersing and dissolving thedry carrier materials in solvent until free of lumps. When using wateras the solvent, it may be desirable to warm the water (e.g., toapproximately 50° C.) prior to adding the carrier material. The flavoris then added under constant agitation until a homogeneous mixture isobtained. The emulsion may be further subjected to high shear orhomogenized to reduce oil droplet size prior to spray drying.

In certain embodiments, the emulsion contains between 40% and 70% drysolid material (including the flavor), or more preferably between 55%and 65% dry solid material (including the flavor). The amount of drysolid material can be adjusted by using more or less water depending onthe solubility of the carrier material and various factors related toefficient operation of the spray dryer. For example, the type and amountof carrier, amount of water, and/or amount of flavor can be adjusted sothat the resulting emulsion has a viscosity suitable for feeding into aspray dryer to provide liquid droplets having a mean particle size (meanvolume diameter) of between 10 μm and 200 μm. For example, when usingspray nozzles, such as a three-fluid nozzle and a four-fluid nozzle, theviscosity of the feed slurry is preferably 500 cps or less, preferably200 cps or less, and more preferably 80 cps or less. For a rotaryatomizer (rotary disk), the viscosity is preferably 70,000 cps or less.Moreover, the feed slurry (i.e., emulsion) can be heated (e.g., to nearthe inlet temperature) or cooled (e.g., to 15° C.) immediately beforeadding it to the spray dryer to modify fluidity. In addition, certainflavors, especially those that are more water-soluble, act asplasticizers thereby making processing more difficult due to stickiness.In this respect, the ratios of carrier materials can be modified.Therefore, various factors can be appropriately selected or modified foruse in combination with different spray dry apparatuses.

In addition to the flavor and carrier material, an emulsifier orsurfactant can also be used in the production of the instant spray-driedflavor composition. Examples of suitable emulsifiers or surfactantsinclude, but are not limited to, lecithins, sucrose esters, proteins,gums, soap-bark extract, saponins, and the like. Moreover, a variety ofsolvents can be used in the instant spray-dried flavor composition. Suchsolvents include, volatiles and nonvolatiles but are not limited toalcohol (e.g., ethanol), ethyl acetate, acetone, triglycerides,vegetable oils, animal fats, and triacetin.

Commercially available spray dryers can be used as in the practice ofthe present invention. For example, a spray dryer with a verticalparallel flow function can be used. The spray dryer should be a systemwith a dehumidifying and drying function. For example, a spray dryercapable of blowing a high volume of desiccated air with a dew point ofless than 5° C. is particularly preferable. For a spray dryer with nodehumidifying and drying function, the spray dryer is inevitablyarranged with a dry dehumidifier, e.g., a honeycomb-type rotarydehumidifier (e.g., Nichias Corporation or Sweden PROFLUTE Corporation).Suitable spray dryers include the micromist spray dryer and the hybridgranulator series manufactured by Fujisaki Electric Co., Ltd.; thefluidized spray dryer FSD with internal fluid bed as manufactured byNiro Corporation; the fluid granulation spray dryer and L-8 type spraydryer manufactured by Ogawara (Japan); the DL-21 type and GB-21 typespray dryers manufactured by Yamato Scientific Co., Ltd., and AnhydroSpray Bed Dryer manufactured by SPX Corporation.

In particular embodiments, the spray dryer is capable of generatingliquid droplets (particles) having a mean particle size (mean volumediameter) of between about 10 μm to about 200 μm. Specifically, it ispreferred to carry out spray drying with a spray dryer with a spraynozzle capable of generating a large volume of liquid droplets having amean particle size of between about 10 μm to about 200 μm, preferablyabout 20 μm to about 150 μm, and more preferably about 30 μm to about100 μm. When the liquid droplets are dried, a dry powder having a meanparticle size (mean volume diameter) of about 10 μm to about 100 μm ispreferred for retention of the flavor oil.

Among the operation conditions of the spray drying apparatus, in certainembodiments the outlet temperature of the spray drying apparatus isbetween 20° C. and 60° C., preferably 30 to 60° C., and more preferably40 to 60° C. For the purposes of this invention, the outlet temperatureof the spray dryer means the product temperature of the dry powder inthe vicinity of the powder collection part of the spray dryer. For thespray dryer of the vertical parallel flow type, the outlet temperaturemeans the temperature (exhaust gas temperature) at the exhaust partthereof.

In other embodiments of this invention, the average inlet airtemperature of the spray drying apparatus is less than 100° C. Incertain embodiments, the average inlet air temperature of the spraydrying apparatus is in the range of 40° C. to 99° C., more preferably60° C. to 99° C. and most preferably 80° C. to 99° C. For the purposesherein, the average inlet air temperature is a sum total of all inletair streams, e.g., main chamber inlet air and the inlet air to the fluidbed(s).

As a particular feature of the instant invention, it is desirable thatproduction parameters including temperature, pressure and humidity, arecontrolled to achieve an air inlet dew point in the range of −10° C. to5° C. In particular embodiments, the air inlet dew point of the spraydrying apparatus is 5° C. or less, preferably 0° C. or less, morepreferably is −5° C. or less, and most preferably −7.5° C. or less. Asis known in the art, dew point temperature is a function of airtemperature and % RH and can be determined using a psychrometric chartor calculator. Dew point temperature is important as it correspondsdirectly to the actual amount of water in the air on a mass basis.

Once the spray-dried flavor composition is dried or partially dried inthe spray drier, the resulting powder can be used in the production offood product, pharmaceuticals, consumer products and the like.Alternatively, particular embodiments feature the additional step offurther drying the spray-dried flavor composition in a fluid-bed chamberattached at the outlet of the spray dryer. Accordingly, certainembodiments feature the use of an integrated fluid-bed spray dryer toproduce the instant spray-dried flavor composition. This secondarydrying can, e.g., further remove entrapped solvent, residual moisture,and/or water of molecular hydration, to provide a composition of powderparticles with significantly lower moisture content that is stable instorage, e.g., for extended periods at ambient temperatures.

In accordance with this embodiment, the temperature of the air supplyingthe fluid-bed unit is maintained at or below the outlet temperature ofthe spray dryer in order to maintain the benefit of volatile flavorretention. Thus, the inlet temperature of the fluid-bed unit is between40° C. and 99° C., preferably 50 to 95° C., and more preferably 60 to90° C.; and the inlet dew point is in the range of −10 to 5° C.

In some embodiments, the fluid-bed has a single zone. In otherembodiments, the fluid-bed unit has one, two, three or more zones,wherein each zone has a different temperature and air flow rate. Incertain embodiments, the fluid-bed unit has three zones, each varying intemperature by at least 10° C. In particular embodiments, the fluid-bedunit has three zones, each varying in temperature by 10° C. to 20° C. Byway of illustration, dry powder from a spray dryer with an outlettemperature of 60° C. could have a first fluid-bed zone at 60° C., asecond bed zone of 45° C. and a third zone of 25° C.

Secondary drying can continue, e.g., for about 5 minutes to about 5hours, or about 10 minutes to about 1 hour, and most preferably about 20to 40 minutes until residual moisture is reduced to a desired level. Inparticular embodiments, secondary drying continues until the residualmoisture of the powder particles is below 5 percent.

As used herein, “dry,” “dried,” and “substantially dried” encompassthose compositions with from about 0% to about 15% water. Preferably,the instant composition will have a water activity of 0.1 to 0.6, ormore desirably 0.2 to 0.5, and most preferably from 0.2 to 0.4 whereinsaid levels of dryness can be achieved with or without secondary drying.

Drying can also occur in the total or partial absence of ambient air. Inthis respect, drying can occur in the presence of CO₂ or other dryinggases (e.g., nitrogen). Accordingly, in particular embodiments, the airof the spray dryer is partially or wholly composed of carbon dioxide ornitrogen. In accordance with this embodiment, partial carbon dioxide ornitrogen is intended to mean a level in the range of 80-99% carbondioxide and/or nitrogen.

Once the spray-dried flavor composition reaches the desired level ofdryness, it can be used in a variety of consumer, food, orpharmaceutical products. In particular, the instant spray-dried flavorcomposition finds application in gums, confections, oral care products,beverages, snacks, dairy products, soups, sauces, condiments,detergents, fabric softeners and other fabric care products,antiperspirants, deodorants, talc, kitty litter, hair care and stylingproducts, personal care products, air fresheners, cereals, baked goodsand cleaners. In specific embodiments, the instant spray-dried flavorcomposition is used in flavoring chewing gum and beverages.Additionally, the spray-dried powder may be further processed byextrusion, coating, agglomeration, blending, compaction to impartadditional functionality or benefits. While the instant invention isdescribed in terms of the spray drying technique, the instant inventioncan employ other drying technologies or processes wherein the use of lowhumidity and temperature conditions result in improved product qualitythrough volatile retention.

Other modifications of this invention will be readily apparent to thoseskilled in the art. Such modifications are understood to be within thescope of this invention. As used herein, all percentages are weightpercent unless otherwise noted, L is understood to be liter, kg isunderstood to be kilogram, and g to be gram. In addition, the amounts,sizes, temperatures and percentages provided herein are understood toinclude exact numbers and approximations.

The following examples are provided as specific embodiments of thepresent invention.

Example 1 Formulations for Dry Flavor Powders

A comparison between modified formulas and conventional control formulaswas conducted. Exemplary Control and Modified formulas of dry flavorpowders are listed in Table 2.

TABLE 2 Component Control Modified Control Modified Orange Flavor 20%16% Berry Flavor 11% 16% Modified starch 10% 8% 72% 8% Carbohydrates 70%76% 17% 76% (e.g., sugar, corn syrup, maltodextrin)

Control powders were produced by a conventional process conditions andModified powders were produced by the instant modified process (FIG. 5),according to the conditions listed in Table 3. In both cases, aconventional spray dryer without an integrated fluid-bed was used.

TABLE 3 Spray Dryer Operating Parameter Standard Modified Inlet airtemperature (° C.) 170-210 <100 Inlet air humidity (g H₂O/kg  2-18 0-4dry air) Outlet air temperature (° C.)  80-100 35-55 Outlet air humidity(g H₂O/kg 45-55 10-20 dry air) Atomizer type Rotary Rotary Disc or DiscNozzle

All formulations ran well with minimal hold-up, sticking, or otherissues in the conventional spray dryer.

Example 2 Retention of Volatile Compounds in Modified Orange FlavorFormulation

Using GC-FID (gas chromatography-flame ionization detector) analysis,the volatile profile of the Orange Flavor formulations in Example 1 wasdetermined. This analysis indicated that the retention of specificvolatile materials for the Modified powder compared to the level in theemulsion were approximately 72%, 75%, and 52% for ethyl propionate,ethyl butyrate, and acetaldehyde, respectively. Table 4 indicated theratio of volatiles retained in the Modified powder in comparison to theControl powder. Sensory tests showed benefit of the Modified powder overthe Control powder in a beverage tasting solution (significantly greateroverall aroma and orange flavor; FIG. 1) and in chewing gum(significantly greater orange flavor intensity at the 30 and 60 secondintervals; FIG. 2).

TABLE 4 Ethyl Ethyl Orange Flavor Propionate Butyrate AcetaldehydeModified 2.3 1.6 1.8 Control 1.0 1.0 1.0

Example 3 Retention of Volatile Compounds in Modified Berry FlavorFormulation

Using GC-FID analysis, the volatile profile of the Berry Flavorformulations in Example 1 was determined. This analysis indicated thatthe retention of specific volatile materials for the Modified powdercompared to the level in the emulsion were approximately 24%, 35%, and87% for dimethyl sulfide, ethyl acetate, and ethyl butyrate,respectively. Table 5 indicated the ratio of volatiles retained in themodified powder in comparison to the Control powder. Sensory testsshowed benefit of the Modified powder over the Control powder in abeverage tasting solution (significantly greater berry aroma and flavor,among others; FIG. 3) and in chewing gum (significantly greater berryflavor intensity at the 30 and 60 second intervals; FIG. 4).

TABLE 5 Dimethyl Ethyl Ethyl Berry Flavor Sulfide Acetate ButyrateModified 12.7 13.4 4.5 Control 1.0 1.0 1.0

Example 4 Effects of Dryer Process Temperatures

To determine the effect of dryer process temperatures on the physicalproperties and flavor quality of a citrus flavor, different spray dryerair inlet and outlet temperatures were utilized. The resulting volatilecompound content, and flavor strength and aroma as determined by anexpert panel are presented in Table 6.

TABLE 6 Inlet/Outlet Acetaldehyde Flavor Aroma Temperature Water ContentStrength Strength (° C.) activity (% of Nominal) Ranking Ranking 190/900.16 37 1  1   93/45 0.27 42 2* 2* *2 = higher.

In addition to the above results, both spray-dried compositionsexhibited free-flowing properties after 7 weeks at 40° C. in a closedcontainer. These results indicate that an air inlet temperature below100° C. reduces loss of volatile flavor compounds, provides improvedsensory intensity, while maintaining water activity of the product at alevel that prevents caking when exposed to above ambient temperatures.

Example 5 Stability of Fruit and Mint Flavors in Chewing Gum

The stability of apple and mint flavors in chewing gum were evaluated.Flavor compositions were spray-dried in accordance with the instantmethod, incorporated into chewing gum, and the stability of the flavorwas evaluated by an expert panel after storage at 32° C. for 2 or 12weeks or 21° C. for 12 weeks. The results of prototype apple-flavoredgum, as compared to a control, are presented in Table 7 and FIG. 6. Thecontrol samples were spray dried flavors processed using conventionaldrying conditions.

TABLE 7 Prototype Flavor Control Flavor Stability Stability Apple 32° C.21° C. 32° C. 21° C. Flavored Gum 2 weeks 12 weeks 12 weeks 2 weeks 12weeks 12 weeks Candy Banana 4.5 4.5 4 4 2 3 Green Apple 5.5 4 4.5 3 2 3Ripe Estery 6 5 5.5 4 3 4 Sweet n.d. 6 6 n.d. 5 5 Sour n.d. 4 4 n.d. 33.5 Salivating n.d. 4 5 n.d. 3 4 Astringent n.d. 3 3 n.d. 2.5 3 Scale:10-point scale (10 = highest). Expert panel of four testers. n.d. = notdetermined.

The analysis presented in Table 7 indicates that the apple flavorproduced by the instant method was as stable as a conventionalspray-dried composition at 21° C. (12 weeks) or 32° C. (12 weeks).However, the impact of the apple flavor produced by the instant methodwas stronger after storage at 32° C. for 12 weeks than that of theconventional spray-dried composition stored at 21° C. for 12 weeks.

The results of prototype mint-flavored gum, as compared to a control,are presented in Table 8.

TABLE 8 Prototype Flavor Control Flavor Stability Stability Mint 32° C.21° C. 32° C. 21° C. Flavored Gum 2 weeks 12 weeks 12 weeks 2 weeks 12weeks 12 weeks Peppermint 6 4.5 5.5 4.5 3 3.5 Menthol 5.5 4.5 5.5 5.5 33.5 Sweet Creamy 5 4 4.5 4.5 3.5 3.5 Sweet n.d. 6.5 7 n.d. 6 7 Bittern.d. 1 1 n.d. 1 1 Astringent n.d. 1 1 n.d. 1 1 Off-note n.d. 0 0 n.d. 13 (plastic) Scale: 10-point scale (10 = highest). Four testers. n.d. =not determined.

The analysis presented in Table 8 indicates that the mint flavorproduced by the instant method was as stable as a conventionalspray-dried composition at 21° C. (12 weeks) or 32° C. (12 weeks).However, the impact of the mint flavor produced by the instant methodwas stronger after storage at 32° C. for 12 weeks than that of theconventional spray-dried composition stored at 21° C. for 12 weeks.Overall, the results of this analysis indicated that the desirablesensory attributes of apple and mint flavors were better maintained inchewing gum using the prototype flavor over 12 weeks at 32° C.

Example 6 Stability of Raspberry Flavor in Powdered Soft Drink Mix

The stability of raspberry flavor in powdered soft drink mix wasevaluated. A raspberry flavor composition was spray-dried in accordancewith the instant method, incorporated into a powdered soft drink mix,and the stability of the flavor was evaluated by an expert panel afterstorage for 8 weeks at 38° C. The results of the prototype soft drinkmix containing the instant spray-dried flavor composition, as comparedto a control, are presented in Table 9. The control sample was a spraydry flavor processed using conventional drying conditions.

TABLE 9 Degree of Sample Difference* Description Prototype 9 Nooff-notes present. Flavor attributes similar to refrigerated reference.Control 7 Lacking fullness, sweetness, loss of impact and juicinesscompared to refrigerated reference. *Scale: 1-3: very large difference,off-notes present; 10: not different from refrigerated reference.

This analysis indicated that after 8 weeks of accelerated storage, theraspberry prototype maintained flavor quality.

Example 7 Evaluation of Savory Broths

Spray-dried flavor compositions, prepared in accordance with the instantmethod, were incorporated into savory broths and attributes of thebroths were assessed by a panel of consumers. The attributes of theprototype broths, as compared to a control, are presented in Table 10.The control broths were prepared from spray dry flavors processed usingconventional drying conditions.

TABLE 10 Flavor % Preference for Attributes** Type Prototype* Prototypevs. Control Chicken 77 More white meat flavor, (N = 65, p = 0.0001)fresher, more balanced, rounder flavor, more overall aroma Beef 59 Moreoverall aroma, more (N = 63, p = 0.17) roasted flavor, bolder flavor,more memorable *Paired comparison forced choice preference test amongcategory users. **Significantly different at greater than or equal to90% confidence interval.

Consumer data showed statistically significant preference for theprototype flavors. This is further supported by the attributes selectedby consumers to describe the flavor quality of the prototypes.

Example 8 Sensory Stability of Neat Powders in High Barrier Packaging

The stability of various flavor prototypes in high barrier packaging(FRESHTEK) was assessed after storage for 6, 12, or 18 weeks at 40° C.The attributes of the prototype powders are presented in Table 11.

TABLE 11 Description* Prototype 6 weeks 12 weeks 18 weeks Peach 11-71Acceptable Acceptable Acceptable Apple 11-58 Acceptable AcceptableBorderline Slight off-notes Slight off-notes, noticeably weaker thanreference Orange Acceptable Acceptable Acceptable Valencia No oxidizedNo oxidized notes 11-299 notes Lime 11-331 Acceptable AcceptableBorderline No oxidized No oxidized notes, slightly notes, noticeablyweaker than weaker than reference reference Lemon Acceptable AcceptableAcceptable Brazilian No oxidized No oxidized notes 11-315 notes *Expertpanel evaluation, reference sample was kept frozen during storage study.

What is claimed is:
 1. A spray-dried flavor composition comprising aspray-dried flavor that contains volatile compounds wherein the volatilecompounds are present in an amount that is at least 20% of the volatilecompounds originally contained in the flavor.
 2. The spray-dried flavorcomposition of claim 1, wherein the volatile compounds areacetaldehydes, dimethyl sulfides, ethyl acetates, ethyl propionates,methyl butyrates, or ethyl butyrates.
 3. The spray-dried flavorcomposition of claim 1, wherein the volatile compounds have a boilingpoint of less than 200° C., less than 100° C., or less than 60° C. 4.The spray-dried flavor composition of claim 1, further comprising acarrier material.
 5. The spray-dried flavor composition of claim 1,wherein the water activity of the composition is in the range of 0.1 to0.6 or in the range of 0.2 to 0.4.
 5. The spray-dried flavor compositionof claim 1, wherein said composition provides a high intensity flavor.6. The spray dried flavor composition of claim 5, wherein the highintensity flavor is incorporated into gums, confections, oral careproducts, beverages, snacks, dairy products, soups, sauces, condiments,detergents, fabric softeners and other fabric care products,antiperspirants, deodorants, talc, kitty litter, hair care and stylingproducts, personal care products, air fresheners, cereals, baked goodsor cleaners.
 7. The spray dried flavor composition of claim 5, whereinthe high intensity flavor is incorporated into a chewing gum orbeverage.
 8. A spray-dried flavor composition produced by spray drying aflavor that contains volatile compounds in a spray dryer having an inlettemperature of less than 100° C. and an air inlet dew point −10° C. to5° C., wherein the volatile compounds are present in the spray-driedflavor composition in an amount that is at least 20% of the volatilecompounds originally contained in the flavor.
 9. The spray-dried flavorcomposition of claim 8, wherein the spray-dried flavor composition isfurther dried in a fluid bed chamber attached at the spray dryer outlet,wherein the temperature of the air of the fluid-bed unit is at or belowthe outlet temperature of the spray dryer.
 10. The spray-dried flavorcomposition of claim 8, wherein the volatile compounds areacetaldehydes, dimethyl sulfides, ethyl acetates, ethyl propionates,methyl butyrates, or ethyl butyrates.
 11. The spray-dried flavorcomposition of claim 8, wherein the volatile compounds have a boilingpoint of less than 200° C., less than 100° C., or less than 60° C. 12.The spray-dried flavor composition of claim 8, wherein the flavorfurther comprises a carrier material.
 13. The spray-dried flavorcomposition of claim 8 or 12, wherein the flavor further comprises asolvent.
 14. The spray-dried flavor composition of claim 13, wherein thesolvent is a volatile solvent.
 15. The spray-dried flavor composition ofclaim 13, wherein the flavor and carrier material comprise 40% and 70%as dry solid material of the total composition.
 16. The spray-driedflavor composition of claim 13, wherein said flavor is prepared as anemulsion and the volatile compounds are present in the emulsion in anamount that is at least 80% of the volatile compounds originallycontained in the flavor.
 17. The spray-dried flavor composition of claim8, wherein air of the spray dryer is partially or wholly nitrogen orcarbon dioxide.
 18. The spray-dried flavor composition of claim 8,wherein the air inlet temperature is in the range of 40° C. to 99° C.19. The spray-dried flavor composition of claim 8, wherein the wateractivity of the composition is in the range of 0.1 to 0.6.
 20. Thespray-dried flavor composition of claim 8, wherein said compositionprovides a high intensity flavor.
 21. The spray-dried flavor compositionof claim 20, wherein the high intensity flavor is incorporated intogums, confections, oral care products, beverages, snacks, dairyproducts, soups, sauces, condiments, detergents, fabric softeners andother fabric care products, antiperspirants, deodorants, talc, kittylitter, hair care and styling products, personal care products, airfresheners, cereals, baked goods or cleaners.
 22. The spray-dried flavorcomposition of claim 20, wherein the high intensity flavor isincorporated into a chewing gum or beverage.
 23. A stable spray-driedflavor composition produced by spray drying a flavor that that containsvolatile compounds in a spray dryer having an inlet temperature of lessthan 100° C. and an air inlet dew point −10° C. to 5° C., wherein thevolatile compounds are present in the spray-dried flavor composition inan amount that is at least 20% of the volatile compounds originallycontained in the flavor.
 24. The stable spray-dried flavor compositionof claim 23, wherein the stable spray-dried flavor composition isfurther dried in a fluid bed chamber attached at the spray dryer outlet,wherein the temperature of the air of the fluid-bed unit is at or belowthe outlet temperature of the spray dryer.
 25. The stable spray-driedflavor composition of claim 23, wherein the volatile compounds areacetaldehydes, dimethyl sulfides, ethyl acetates, ethyl propionates,methyl butyrates, or ethyl butyrates.
 26. The stable spray-dried flavorcomposition of claim 23, wherein the volatile compounds have a boilingpoint of less than 200° C., less than 100° C., or less than 60° C. 27.The stable spray-dried flavor composition of claim 23, wherein theflavor further comprises a carrier material.
 28. The stable spray-driedflavor composition of claim 23 or 27, wherein the flavor furthercomprises a solvent.
 29. The stable spray-dried flavor composition ofclaim 28, wherein the solvent is a volatile solvent.
 30. The stablespray-dried flavor composition of claim 28, wherein the flavor andcarrier material comprise 40% and 70% as dry solid material of the totalcomposition.
 31. The stable spray-dried flavor composition of claim 28,wherein said flavor is prepared as an emulsion and the volatilecompounds are present in the emulsion in an amount that is at least 80%of the volatile compounds originally contained in the flavor.
 32. Thestable spray-dried flavor composition of claim 23, wherein air of thespray dryer is partially or wholly nitrogen or carbon dioxide.
 33. Thestable spray-dried flavor composition of claim 23, wherein the air inlettemperature is in the range of 40° C. to 99° C.
 34. The stablespray-dried flavor composition of claim 23, wherein the water activityof the composition is in the range of 0.1 to 0.6.
 35. The stablespray-dried flavor composition of claim 23, wherein said compositionprovides a high intensity flavor.
 36. The stable spray-dried flavorcomposition of claim 35, wherein the high intensity flavor isincorporated into gums, confections, oral care products, beverages,snacks, dairy products, soups, sauces, condiments, detergents, fabricsofteners and other fabric care products, antiperspirants, deodorants,talc, kitty litter, hair care and styling products, personal careproducts, air fresheners, cereals, baked goods or cleaners.
 37. Thestable spray-dried flavor composition of claim 35, wherein the highintensity flavor is incorporated into a chewing gum or beverage.
 38. Amethod for producing a spray-dried composition capable of retainingvolatile compounds comprising spray drying a flavor containing volatilecompounds in a spray dryer having an inlet temperature of less than 100°C. and an air inlet dew point −10° C. to 5° C. to obtain a spray-driedflavor composition, wherein the volatile compounds are present in thespray-dried flavor composition in an amount that is at least 20% of thevolatile compounds originally contained in the flavor.
 39. The method ofclaim 38, further comprising drying the spray-dried flavor compositionin a fluid-bed chamber attached at the spray dryer outlet, wherein thetemperature of the air of the fluid-bed unit is at or below the outlettemperature of the spray dryer.
 40. The method of claim 38, wherein thevolatile compounds are acetaldehydes, dimethyl sulfides, ethyl acetates,ethyl propionates, methyl butyrates, or ethyl butyrates.
 41. The methodof claim 38, wherein the volatile compounds have a boiling point of lessthan 200° C., less than 100° C., or less than 60° C.
 42. The method ofclaim 38, wherein the flavor further comprises a carrier material. 43.The method of claim 38 or 42, wherein the flavor further comprises asolvent.
 44. The method of claim 43, wherein the solvent is a volatilesolvent.
 45. The method of claim 43, wherein the flavor and optionalcarrier material comprise 40% and 70% as dry solid material of the totalcomposition.
 46. The method of claim 43, further comprising preparingthe flavor as an emulsion, wherein the volatile compounds are present inthe emulsion in an amount that is at least 80% of the volatile compoundsoriginally contained in the flavor.
 47. The method of claim 38, whereinthe air inlet temperature is in the range of 40° C. to 99° C.
 48. Themethod of claim 38, wherein the water activity of the spray-dried flavorcomposition is in the range of 0.1 to 0.6.